Abstract: A solenoid for a vehicle starter includes a pull-in coil made of a length of rectangular wire and a hold-in coil adjacent to the pull-in coil. A plunger is configured to move in an axial direction when the pull-in coil made of rectangular wire is energized. The pull-in coil and the hold-in coil are positioned on a spool with the plunger slideably positioned within a central passage of the spool. The plunger is configured to engage a plunger stop when the pull-in coil is energized. In at least one embodiment, the hold-in coil is separated from the plunger stop in the axial direction and the hold-in coil encircles the plunger stop.

Abstract: A solenoid for a vehicle starter comprises a pull-in coil and a hold-in coil positioned axially adjacent to the pull-in coil. A plunger is positioned within the pull-in coil and configured to move in an axial direction when the pull-in coil is energized. The plunger is separated from a plunger stop in the axial direction by an air gap when the pull-in coil and the hold-in coil are not energized. When the pull-in coil and hold-in coil are energized, a shoulder of the plunger moves in an axial direction toward the plunger stop. The pull-in coil is positioned in the solenoid such that it is removed from the plunger stop in the axial direction. In contrast, the hold-in coil encircles the plunger stop.

Abstract: Disclosed is a rotor assembly for an electric machine includes a rotor core. The rotor core has at least one magnet slot with an increasing slot width as radial distance from a rotor shaft increases, and at least one slot lip extending at least partially across the slot width. The rotor assembly also includes at least one permanent magnet located in at least one magnet slot, the magnet having an increasing magnet width as radial distance from a rotor shaft increases. The rotor assembly further includes a retainer disposed in the magnet slot radially between the magnet and the at least one slot lip. Also disclosed is a method of securing at least one permanent magnet in a rotor assembly of an electric machine.

Abstract: An electric machine including a housing, and a stator mounted relative to the housing. The stator includes a body including a first end portion that extends to a second end portion and a plurality of stator windings that extend between the first and second end portions. A sleeve member is mounted to the stator and covers a portion of the stator windings at one of the first and second end portions. The sleeve member is configured and disposed to guide a coolant over the portion of the stator windings to remove heat from the stator.

Abstract: A method for monitoring remaining life of an electric machine for a motor vehicle includes sensing a temperature of a component of the electric machine at one or more time intervals. A percentage of life of the component consumed at each time interval is calculated and the percentages of life consumed are summed to determine a total percentage of life consumed. The total percentage of life consumed is compared to a selected threshold. A life monitor system for an electric machine for a vehicle includes a temperature sensor secured to a component of the electric machine. An engine control unit is operably connected to the temperature sensor and is configured to calculate a remaining life of the component of the electric machine compared to a selected threshold, based on temperature data from the temperature sensor.

Abstract: A permanent magnet rotor assembly for an electric machine includes a rotor core including one or more axially-extending openings and one or more permanent magnets located in the one or more axially-extending openings defining one or more gaps between the one or more permanent magnets and the one or more axially-extending openings. One or more thermally-conductive bars are located in the one or more gaps to transfer thermal energy from an interior of the rotor assembly toward an axial end of the rotor assembly.

Abstract: An electric machine includes a core with a plurality of slots. Electric conductors are positioned within the slots with connection ends extending from the in-slot portions. A plurality of insulation sleeves separate the plurality of electric conductors. Each insulation sleeve substantially covers one entire conductor, including the in-slot portions and the connection ends of the conductor. A tip portion on each connection end remains uncovered by the insulation sleeve and is electrically connected to another tip portion on another conductor. Air passages are formed between the plurality of insulation sleeves at the in-slot portions and at the connection ends of the plurality of electric conductors.

Abstract: An electric machine including a housing and a stator arranged within the housing. The stator includes a body having a first end that extends to a second end through an intermediate portion. The intermediate portion includes an inner diametric surface and an outer diametric surface. A sleeve member is arranged on the outer diametric surface of the stator. The sleeve member includes body member having an inner diametric region that extends to an outer diametric region through an intermediate region. The sleeve member defines a flux carrying member having a magnetic flux flow path that passes magnetic flux from the stator to the outer diametric region.

Abstract: Embodiments of the invention provide an electric machine module and a method for cooling an electric machine. The electric machine module comprises the electric machine including a stator with stator end turns and a housing with at least two removably-coupled frame members. Each of the at least two removably-coupled frame members include an inner wall, an outer wall, and a coolant cavity defined between the inner wall and the outer wall. The coolant cavity can be positioned substantially around one of the stator end turns radially and substantially beside the one stator end turn axially.

Abstract: Embodiments of the invention provide an electric machine module and a method for cooling an electric machine. The electric machine module comprises the electric machine including a stator with stator end turns, a through bolt, and a housing with at least two removably-coupled frame members. Each of the at least two removably-coupled frame members include an inner wall, an outer wall, a coolant cavity defined between the inner wall and the outer wall, and a bolt channel. The coolant cavity can be positioned substantially around at least one of the stator end turns radially. The bolt channel can be positioned through a portion of each of the at least two removably-coupled frame members and can be located radially inward from an outer substantially circular periphery of the housing.

Abstract: Embodiments of the invention provide an electric machine module and a method for cooling an electric machine module. The electric machine module includes an electric machine including a stator with stator end turns, a liquid-cooled housing at least partially enclosing the electric machine, and a potting material in contact with and at least partially surrounding the stator end turns. The method includes potting at least some of the stator end turns with the potting material to provide a thermally-conductive path from the stator end turns to the housing and circulating a coolant through the housing to at least remove heat energy conducted from the stator end turns to the housing.

Abstract: Embodiments of the invention provide an electric machine module and a method for cooling an electric machine. The electric machine module includes the electric machine including a stator with stator end turns and a housing enclosing the electric machine. An inner wall of the housing defines a machine cavity. The electric machine module also includes a cover coupled to the housing and extending radially inward into the machine cavity. The cover and the stator end turns define a stator cavity which is in fluid communication with the machine cavity.

Abstract: Embodiments of the invention provide an electric machine module and a method for cooling an electric machine. The apparatus and method include providing the electric machine including a rotor and a stator with stator end turns and enclosing at least a portion of the electric machine within a housing. The method also includes introducing a coolant into a machine cavity, directing the coolant toward the stator end turns, and returning a portion of the coolant which flows past the stator end turns back toward the stator end turns using a rotating agitator member operatively coupled to the rotor.

Abstract: Embodiments of the invention provide an electric machine module and a method for cooling an electric machine. The electric machine module includes an electric machine and a housing enclosing the electric machine within a machine cavity. The housing can include at least one end cap positioned axially adjacent to the electric machine and including a shroud protruding into the machine cavity. The shroud can include a step with an angled rotor feed path.

Abstract: A solenoid arrangement for a starter motor includes a plunger configured to move in an axial direction and a coil positioned radially outward from the plunger. The coil is wound on a spool that includes a first end and a second end with a hub extending between the first end and the second end. A projection is positioned on the hub of the spool. The coil engages the projection in such a manner that a winding direction of the coil is reversed at the projection.

Abstract: A vehicle alternator comprises a rotor and a stator positioned within a housing. The housing includes a front face, a rear face, and a outer wall extending between the front face and the rear face. The front face includes a plurality of air inlet holes, and the rear face including a plurality of air outlet holes. The outer wall is void of air holes that extend through the outer wall. The rotor is positioned within the housing and configured to rotate about an axis. The stator is positioned within the housing between the rotor and the outer wall of the housing. The stator includes a core with an outer surface, a front end and a rear end. A plurality of substantially axial air passages are positioned between the outer wall of the housing and the outer surface of the stator core.

Abstract: An electric machine includes a stator and a rotor configured to rotate about an axis of rotation in a direction of angular rotation. The rotor includes a first claw-pole segment and an opposing second claw-pole segment. The first claw-pole segment includes a plurality of fingers extending from an end ring. Each finger includes a distal end and a proximal end with the proximal end fixed to the end ring. Each finger also includes an interior side and an exterior side with the exterior side facing the stator. A leading side and a trailing side are defined on each finger by the direction of angular rotation. A chamfer is formed on the exterior trailing side of each finger at the proximal end of the finger.

Abstract: An electrical system for a vehicle comprises a battery including a positive terminal and a negative terminal, and an alternator. The alternator includes a metal housing with a rotor and a stator positioned within the housing. The alternator further includes an electronics package positioned on the alternator housing. The electronics package includes a regulator and a rectifier, the rectifier including a plurality of negative diodes and a plurality of positive diodes. The plurality of positive diodes are positioned on a first diode carrier that is electrically connected to the negative terminal of the battery. The plurality of positive diodes are positioned on a second diode carrier that is electrically connected to the positive terminal of the battery. The first diode carrier is separated from the housing by an electrical insulation member positioned between the first diode carrier and the housing.

Abstract: A solenoid includes a solenoid housing defining a solenoid centerline; and an ignition magnetic switch including an ignition magnetic switch coil disposed at least partially within the housing, the ignition magnetic switch coil having a magnetic field that encompasses the solenoid centerline.

Abstract: Disclosed herein is an electric machine rotor. The rotor includes, a rotatable shaft, a plurality of pole segments attached to the shaft, and a plurality of magnets attached to the plurality of pole segments such that one of the plurality of magnets is positioned circumferentially between adjacent pole segments and each of the plurality of magnets has nonparallel circumferentially opposing sides.